HIOKI DT4261 Digital Multimeter Solar Kit Instruction Manual
- June 17, 2024
- HIOKI
Table of Contents
HIOKI DT4261 Digital Multimeter Solar Kit
Product Information
Specifications:
- Product Name : Electrical Safety Equipment for EV Maintenance
- Models : Z3210, DT4261, IR4059, FT3701, RM3548
- Features : High voltage safety measures, temperature measurement, zero-voltage testing, equipotential bonding, insulation resistance testing
Product Usage Instructions
Shutting Down the HV System:
Before any maintenance or service, follow these steps:
- Perform a visual inspection for motor faults using DTC scan.
- Disconnect the HV bus.
- Measure the surface temperature of HV batteries using an infrared thermometer like FT3701.
- Measure zero-voltage between specific points and chassis ground using a digital multimeter like DT4261.
- Disconnect the HV battery cable and wait at least 10 minutes for system discharge.
After Repair and Inspection:
After repair and inspection:
- Perform equipotential bonding test using a resistance meter like RM3548.
Frequently Asked Questions (FAQ)
-
Q: Why is it important to measure zero-voltage during maintenance?
A: Measuring zero-voltage ensures the safety of personnel by confirming that the vehicle’s high-voltage system is shut down, preventing electric shock. -
Q: How long should I wait after disconnecting the HV battery cable for system discharge?
A: Wait at least 10 minutes for the HV system to discharge. The discharge time may vary, so always check with the vehicle manufacturer for specific guidance.
A Guide on Electrical Safety for EV Maintenance and Service
- Stay safe during EV maintenance
- High voltages make safety for EV maintenance essential. This guide outlines correct procedures and reliable electrical tests to ensure safe operations.
Shutting down the HV system of the vehicle
-
For safety, be sure to carry out a visual inspection and look out for motor faults by performing a DTC (Digital Trouble Codes) scan.
-
Before proceeding to electrical testing and measurement, make sure to shut down*1 the vehicle’s HV (High-voltage) system by disconnecting the service plug or using the switch.
-
The removal of high-voltage components is hazardous work. Ensure that the work is performed by qualified personnel with professional training, following applicable laws and regulations. For details, please follow the operation manual of each vehicle manufacturer.
-
Measure the surface temperature of the HV battery with a non-contact thermometer. In this inspection, check for variations in temperature as well as areas of high temperature. These may indicate issues that need further investigation.
-
INFRARED THERMOMETER FT3701
- The FT3701 is an infrared thermometer with a two-point laser marker that measures the average surface temperature inside a circle formed by the two points.
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This measurement is conducted to prevent electric shock and to make sure that the vehicle is shut down. Safety from electrocution is ensured by measuring the voltage on surfaces that are likely to be touched when unplugging the HV connector.
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In this test, voltage should be measured between specific points and the chassis ground of the vehicle. It should show up as zero volts (0 V).
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DIGITAL MULTIMETER DT4261
- The DT4261’s terminal shutters make it physically impossible to insert the wrong test lead. They prevent overvoltage and electrical shock accidents.
- The LoZ (low input impedance) mode gets rid of the effects of ghost voltages caused by the measurement target’s stray capacitance and the multimeter’s high input impedance. This lets you get accurate readings.
-
After performing a zero-voltage measurement (see below), disconnect the high-voltage (HV) cable and wait at least 10 minutes for the HV system to discharge. To avoid a serious accident, it is necessary to wait for a certain period of time.
-
Take note that the discharge time may vary, so make sure to check with the vehicle manufacturer.
-
After unplugging the HV battery’s connector, make sure that the HV system is shut down.
Flow after repair and inspection
- This test is conducted after high-voltage (HV) components have been installed or replaced. By checking the ability for electricity to flow (conductance/resistance) between all parts and the chassis, this test ensures that the chassis properly functions as a ground to capture stray voltages during and between operation. For this, the resistance is measured at the points where the chassis of the vehicle and the HV components are connected. If the resistance value is high or differs significantly from the value measured before the service work was performed, the connection of the HV component may have been installed incorrectly.
RESISTANCE METER RM3548
- RM3548 is a four-terminal (four-wire Kelvin) DC milliohm meter
- The current applied during testing (500 nA to 1 A) enables accurate measurement of tens of μΩ. This meets the ECE-R100*2 standard’s requirement
- Safety standard for electric powertrains of road vehicles including rechargeable battery systems.
INSULATION TESTER IR4059
- For the HV range (500 V or 1000 V), the IR4059 has a safety feature that requires the technician to unlock in addition to choosing the voltage to prevent unintentional HV accidents
- Stable measurement under capacitive loads
- The test lead with remote switch is equipped with an LED
- The green/red light makes pass/fail judgments instantaneous and easy
- When the repair or inspection is finished, take a zero-voltage measurement on the inverter side and the battery side before safely reconnecting the HV system. After zero-voltage testing, install the high-voltage cable, service plug (a.k.a. switch), and return the vehicle’s HV system to energized status.
RESISTANCE METER RM3548
INSULATION TESTER IR4059
DIGITAL MULTIMETER DT4261
INFRARED THERMOMETER FT3701
CARRYING CASE C0213
- It can accommodate all measuring instruments.
- EV maintenance manual included.
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- HEADQUARTERS
- 81 Koizumi,
- Ueda, Nagano 386-1192 Japan https://www.hioki.com/
- All information correct as of Dec. 4, 2023. Contents are subject to change without notice.
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